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Old January 3rd, 2017, 05:57 PM   #1
stoker100
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Sunroof Delete ::HOWPROBABLYNOTTO::

Well each x-mas break i choose a project to keep me busy, this year is was deleting the sunroof from the probe. Certainly not a fun/interesting project but im sick of it leaking and for some reason i like to torture myself.

1) find a donor roof (from a non sunroof version)


2) remove old sunroof


3) mark out


4) nibble away


5) test fit


6) remove paint (note bog/rust removed in bottom left corner)


7) test fit



8) start the BS welding


points to note:
- i am not an auto-body repair person, i cannot weld well so don't expect a nice next picture!
- i could have sat it flush in the old sunroof hole, i chose to overlap it by approx 10mm.
- the roof curvature appears to be different (the back near the hatch curves off quickly to the sunroof) im not changing this.
- i will paint it myself, if it turns out crap then ill put a wrap over it
- more to come soon.
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Old January 3rd, 2017, 07:05 PM   #2
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For future similar projects -you could get yourself a pneumatic lip former. And there are adhesives known to man that will bond metal to metal nearly as good as a weld. Form a half inch lip all the way around. Glue in cut piece of metal and then you have yourself a flush fit patch with very little body work required. I have a lip former -and it is highly recommended.

If you don't trust bonding glues -you can always add a hole dimpler to your tool collection and use countersunk head rivets along with the bonding glue.\

P.S. Your welding looks pretty good to me so far.
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Old January 3rd, 2017, 08:39 PM   #3
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Quote:
Originally Posted by KLZE Porsche View Post
For future similar projects -you could get yourself a pneumatic lip former. And there are adhesives known to man that will bond metal to metal nearly as good as a weld. Form a half inch lip all the way around. Glue in cut piece of metal and then you have yourself a flush fit patch with very little body work required. I have a lip former -and it is highly recommended.
I looked into the glue and would have gone that way except the roof panel isn't reinforced and it would raise up the panel even further (meaning more bog). I will however be using metal glue from the inside to help increase the overall strength. I also could have formed the lip but if i was going to do that i would have just found an original sunroof panel and welded that in. The metal is VERY thin, less than 0.8mm thick so i didn't want to warp it forming it either.

9) 1/1000th through spot welding, i decided from here to just fill the rest as it was killing me.


10) half way through grinding back the welds, looks like it took 5min but it was closer to half a day


11) where i am leaving it for today.... bog, prime/fill, sand and repeat x10 has worn me out today.


The good new is its getting close to flat from what my eye can see.
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Old January 4th, 2017, 05:07 AM   #4
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Quote:
Originally Posted by stoker100 View Post

The good new is its getting close to flat from what my eye can see.
Looking good to me. I had thought about filling in the dreaded hole on one of mine before -and not because of leaks -but because of air rattling. Mine would make noise at highway speed. And since the top wasn't glass -there was not really any use for it for me. I had tried using it once or twice -but they are actually quite lame. A window down does a far better job of keeping me cool on hot summer days.

Although -I do not have the welding skills that you have (nor the patience). That is a lot of very fine spots that would have been burn-thru holes for me. If I ever do fill one of those on one of mine (hahaha) I will use my lapper and glue technique. But -unless the glass top in my black one leaks -it will remain untouched. I already have far too many projects.

Keep pressing away at it -it looks good and I am anxious to see the finished product. I am amazed that you could even find a spare parts car "down under" to cut a top from. Aren't Probes fairly rare down there?
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Old January 4th, 2017, 06:32 AM   #5
Greg 94 PGT
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The last pic isn't looking too bad.

When I was doing the body work on my pgt, I removed the door lock holes and antenna hole.

It obviously wasn't the amount of welding, grinding, sanding, and filler you are doing. But even the amount I did helped me realize I don't want to do body work ever again.

So I can sympathize with you.
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Old January 4th, 2017, 10:13 PM   #6
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Quote:
Originally Posted by KLZE Porsche View Post
I am amazed that you could even find a spare parts car "down under" to cut a top from. Aren't Probes fairly rare down there?
2000 were imported here, up until about 3 years ago i still saw plenty on the roads. now im lucky to see one a month.

Quote:
Originally Posted by Greg 94 PGT View Post
When I was doing the body work on my pgt, I removed the door lock holes and antenna hole.

It obviously wasn't the amount of welding, grinding, sanding, and filler you are doing. But even the amount I did helped me realize I don't want to do body work ever again.
Years ago i got someone to weld in an Australian 20c coin into my door locks (they fit perfectly) i did the bog/prime work on that and the antenna and they came out perfect. This sunroof project is 10000000000000x more work.
http://i299.photobucket.com/albums/m...ting/day2b.jpg

12) hope nobody works in conditions like i am (39.3c = 103f), ignore the top temp that is the air temp inside my rainwater tank.


13) I hate those little holes that are too big for the primer/filler but too small for the bog! trying to fill those but ended up using bog then sanding back what felt like 100kg of bog with 1600 sandpaper


14) Full coat of filler on the new section of roof


15) sanded that back one last time.... yes there is a dent in the middle of the roof (white part, probably from removing the internal structural support)


Tonight its getting one more coat of filler and that's it. Ive had enough of this project now, im going to go lay down somewhere cool.
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Old January 5th, 2017, 12:51 PM   #7
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Wait a minute... this was the perspex sunroof?
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Old January 5th, 2017, 01:22 PM   #8
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Quote:
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Wait a minute... this was the perspex sunroof?
Yes it was.
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Old January 5th, 2017, 02:01 PM   #9
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Aww
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Old January 16th, 2017, 04:04 PM   #10
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I have not seen this to be done before.
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Old January 16th, 2017, 10:28 PM   #11
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its pretty much done for now, its glossed and ive rubbed it back with 2000 wet and dry, just waiting for a polishing pad to finish it off. came out ok for a rattle can job. will post pics once i complete my next project.
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Old January 23rd, 2017, 02:43 AM   #12
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base coat:


after gloss:


close up (prior to 2000 wet sand and polishing):


all done (and now water resistant!):
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Old January 23rd, 2017, 05:09 AM   #13
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Great job!
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Old January 23rd, 2017, 06:00 AM   #14
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It came out great. Bet you're relieved now.
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Old January 23rd, 2017, 06:09 AM   #15
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Finished product looks great! Nice work.
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Old January 23rd, 2017, 12:58 PM   #16
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That came out a whole lot nicer than I expected. Great job man!
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Old January 24th, 2017, 08:59 PM   #17
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Looks phenomenal!
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Old January 24th, 2017, 11:17 PM   #18
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Thanks everybody, yes came out pretty good and i am relieved its finally done. I rushed the last few days of leave to get it done so its not perfect but its certainly good enough for a 23 year old car.
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Old February 9th, 2017, 08:41 PM   #19
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^^^^ slow learner
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Old February 12th, 2017, 10:29 AM   #20
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It was a lot more work but back in the day when I installed the factory moonroof into my car I removed the whole roof. A lot less body work since the b and c pillars are covered by the glass.
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